Multi-deck, multi-adjust diverter

ABSTRACT

A compact modular mobile aggregate processing system configured with no stand-alone inter-plant conveyors for decreasing the footprint of the system and an infinitely adjustable flow diverter(s) for increasing the control of and variation of output characteristics of the system; the system further including specialized folding conveyors.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional application filed onJun. 22, 2006 and having Ser. No. 60/805,548; and provisionalapplication filed on Nov. 29, 2006 and having Ser. No. 60/867,713, whichare hereby incorporated herein in their entirety by this reference. Thisapplication also claims the benefit of utility application filed on Jun.19, 2007, having Ser. No. 11/765,341 and Issued U.S. Pat. No. 8,162,245;utility application filed on Mar. 26, 2012, having Ser. No. 13/429,819and Issued U.S. Pat. No. 8,403,147; utility application filed on Mar.12, 2013, having Ser. No. 13/848,406 and Issued U.S. Pat. No. 8,979,008;utility application filed on Mar. 12, 2015, having Ser. No. 14/645,632and Issued U.S. Pat. No. 9,849,461; and utility application filed onDec. 22, 2017, having Ser. No. 15/852,791, which are hereby incorporatedherein in their entirety by this reference.

BACKGROUND OF THE INVENTION

This invention relates to aggregate processing systems, rock crushingplants and other road building material processing systems. Morespecifically, this invention relates to mobile rock crushing andaggregate processing plants which are capable of being transported overpublic highways.

Several techniques and numerous equipment arrangements for moving rockcrushing and aggregate processing plants from one location to anotherare known from the prior art. Particularly relevant to the presentinvention is the use of modular aggregate processing and systems wherethe components of the entire system can be broken down and transportedvia semi-trucks to another location. Typically, the modular aggregateprocessing and rock crushing system would be designed to be broken downin numerous trailerable independent units, including road buildingmaterial handling and processing equipment, such as crushers, trommels,screens, etc. and material transport equipment such as conveyors,augers, etc.

While such prior art modular mobile aggregate processing and rockcrushing systems have enjoyed considerable success in the past, they dohave some drawbacks. Such modular mobile aggregate processing and rockcrushing system designs often resulted in considerable setup time andthe use of many semi-tractors to pull all of the units.

One prior art system is described in U.S. Pat. No. 6,935,587 issued toBrock et al. This patent describes a modular aggregate processing androck crushing system which utilizes many trailers to transport thesystem. Inter-crusher/processing module conveyor trailers were used tointerconnect the various crushing or processing stations.

Consequently, a need remains in the industry for an improved modularmobile aggregate processing and rock crushing system which provides forreduced setup and delivery time and expense, as well as reduced spacerequirements (footprints) for the system itself.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a compact system forblending aggregate material.

It is a feature of the present invention to utilize a sliding swing gatebending gate.

It is an advantage of the present invention to provide for compactadjust-ability of proportionally directing aggregate material.

Accordingly the present invention is:

A mobile screen comprising:

-   -   a plurality of decks for separating aggregate material having        differing dimensional characteristics;    -   aggregate material diverter wherein flow of material        therethrough is substantially aided by gravity;    -   wherein said aggregate material diverter is an infinitely        adjustable material diverter, capable of dividing input flows        therein to a plurality of output flows; said infinitely        adjustable material diverter comprises: a gate which is        configured to move, in a first manner, to block, at least        portions of a first passage, while permitting aggregate material        to flow through a second passage; and said gate further        configured to move, in a second manner, across an area below a        material flow so that movement of said gate, in said second        manner, results in an infinitely adjustable percentage of        permissible flow through said first passage and said second        passage; and    -   a vehicular structure supporting said plurality of decks and        said aggregate material diverter.

Additionally, the present invention is:

A mobile screen comprising:

-   -   a stacked series of decks for separating aggregate material        having differing dimensional characteristics;    -   a series of aggregate material diverters wherein flow of        material therebetween is substantially aided by gravity;    -   wherein one of said series of aggregate material diverters is an        infinitely adjustable material diverter, capable of dividing        input therein to a plurality of output flows in any increment        from all input to none of the input; and    -   a vehicular structure supporting said stacked series of decks        and said series of aggregate material diverters, where said        vehicular structure is configured to be transported on a public        highway.

BRIEF DESCRIPTION OF THE DRAWINGS

In one embodiment, the present invention comprises multiplecrushers/screens which utilize on-board conveyors and further havemultiple common feed and discharge points across the various multiplecrushers/screens.

In the following description of the drawings, in which like referencenumerals are employed to indicate like parts in the various views:

FIG. 1 is a perspective view of a mobile jaw rock crusher of thisinvention.

FIG. 2 is a partially exploded view of a mobile jaw rock crusher of FIG.1.

FIG. 3 is a perspective view of an underside portion of the mobile jawrock crusher of FIGS. 1 and 2, where a stowable jack is shown in thedeployed position.

FIG. 4 is a schematic diagram of the pneumatic system of the presentinvention.

FIG. 5 is an overhead perspective view of a “mini plant” embodiment ofthe system of the present invention, which shows fewer components and asmaller footprint.

FIG. 6 is a plant view of the system of the present invention disposedinterior of an array of stockpiles. The plant shown is a “regular plant”embodiment of the system of the present invention which shows morecomponents and a somewhat larger footprint than the mini plant.

FIG. 7 is a perspective view of the system of FIG. 6.

FIG. 8 is an upwardly looking perspective view of the output end of thescalping screen 300.

FIG. 9 is a close-up view of the blending area of the output end of thescalping screen 300.

FIG. 10 is a schematic flow diagram graphically showing flows ofmaterial through the innovative system of the present invention. Thedashed lines represent paths of material which did not flow in therepresentative evaluation.

FIG. 11 is a perspective view of the portion of the scalping screen 300of the present invention with components thereof removed to betterreveal portions of the system which transport bottom deck overs.

FIG. 12 is a perspective view of the portion of the scalping screen 300of the present invention with components thereof removed to betterreveal portions of the system which transport top and optionally middledeck overs.

FIG. 13 is a perspective view of the portion of the scalping screen 300of the present invention with components thereof removed to betterreveal portions of the system which transport middle deck overs.

FIG. 14 is a perspective view of the portion of the scalping screen 300of the present invention with components thereof removed to betterreveal portions of the system which transport bottom deck throughs orfines.

FIG. 15 is a top view of a sliding swing gate blending assembly of thepresent invention.

FIG. 16 is a top, front right side perspective view of the sliding swinggate blending assembly of FIG. 15, where the swing gate is disposed inan intermediate position between backward flow and forward flow.

FIG. 17 is a cross-sectional view of the sliding swing gate blendingassembly of FIGS. 15 and 16 taken on a central line when the swing gateis in a backward flow direction position. The lines with arrowheads andopposing bulbous ends thereon show flow directions of material throughthe sliding swing gate blending assembly 1500.

FIG. 18 is a cross-sectional view of the sliding swing gate blendingassembly of FIGS. 15 and 16 taken on a central line when the swing gateis in a forward flow direction position. The heavy black lines withheavy black arrowheads and opposing heavy black bulbous ends thereonshow flow directions of material through the sliding swing gate blendingassembly 1500.

FIG. 19 is an elevation view of a folding conveyor of the presentinvention disposed next to a hopper or other structure for receivingmaterial therein. The folding conveyor is shown in an operatingposition.

FIG. 20 is an elevation view of a folding conveyor of the presentinvention disposed next to a hopper or material intake location forreceiving material therein. The folding conveyor is shown in an earlytransitional position.

FIG. 21 is an elevation view of a folding conveyor of the presentinvention disposed next to a hopper for receiving material therein. Thefolding conveyor is shown in a midrange transitional position.

FIG. 22 is an elevation view of a folding conveyor of the presentinvention disposed next to a hopper for receiving material therein. Thefolding conveyor is shown in a late transitional position.

FIG. 23 is an elevation view of a folding conveyor of the presentinvention disposed next to a hopper for receiving material therein. Thefolding conveyor is shown in a stowed position.

FIG. 24 is a perspective view of a screen of the present invention whichis shown configured so as to be able to be towed (i.e., the conveyor ofFIGS. 19-23 is fully stowed, as well as other conveyors thereon).

FIG. 25 is an elevation view of a material receiving apparatus withretractable sides, with one shown deployed for use and the other stowedfor transport.

FIG. 26 is a perspective view of a configuration of an output end of afinishing screen of the present invention.

FIG. 27 is a simplified cross-sectional drawing of the finishing screenof FIG. 26 where the dashed and dotted lines represent flows ofmaterials through the screen.

FIG. 28 is a perspective view of a configuration of an output end of ascalping screen of the present invention.

FIG. 29 is a simplified cross-section drawing of the scalping screen ofFIG. 28 where the dashed and dotted lines represent flows of materialthrough the scalping screen.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, where like numerals refer to like matterthroughout, and referring in greater detail, attention is first directedto FIG. 1, where there is shown a bifurcatable crusher 100, having amaterial feed section 110 disposed at a rear end of bifurcatable crusher100 and a rock crusher section 130, which is disposed at the front endof the combined bifurcatable crusher 100. Material feed section 110includes a material feeder section input hopper 112 with material feedersection conveyor 116 and material feeder section folding wings 118,which are used to extend the size of the dumping zone for the materialfeeder section input hopper 112. Folding stowable trailer misfeedprotecting cover 119 is used to protect the trailer from damage causedby misfed material which is intended for the material feeder sectioninput hopper 112, but falls outside the dumping zone and otherwise mightstrike the trailer. Folding stowable trailer misfeed protecting cover119 can be folded and stowed during traveling as shown in the figures.

Material feed section 110 is shown with material feeder section trailerwheels 114. Rock crusher section 130 is shown with rock crusher sectionframe 132, rock crusher 134, rock crusher output conveyor 136, rockcrusher trailer wheels 138, rock crusher trailer rear jack 140, rockcrusher trailer middle jack 142, and rock crusher trailer front jack144. When the bifurcatable crusher 100 is a unified structure, as shownin FIG. 1, it functions as a rock crusher where rocks, concrete andother materials known to be fed into a rock crusher are dropped intomaterial feeder section input hopper 112 and fed by the material feedersection conveyor 116 into the rock crusher 134, where they are processedand output on rock crusher output conveyor 136. The bifurcatable crusher100 is towable as a single non-intermediately articulating trailer.

Now referring to FIG. 2, there is shown the bifurcatable crusher 100after it has been divided into separate material feed section 110 androck crusher section 130. FIG. 2 shows a material feeder trailer jack210 in a deployed position. Material feeder trailer jack 210 ispreferably both retractable (length adjustable) and pivotable viahydraulic power.

Now referring to FIG. 3, there is shown a perspective view lookingupward at the bottom of the material feed section 110, which shows thematerial feeder trailer jack 210 in a deployed position, and also showsthe material feeder section gas-powered hydraulic pump 310, which isintended to provide hydraulic power to operate portions of the materialfeed section 110, such as the material feeder section folding wings 118,the folding stowable trailer misfeed protecting cover 119, foldsmaterial feeder trailer jack 210 and extends material feeder trailerjack 210.

Now referring to FIG. 4, there is shown a pneumatic schematic diagramwhich is divided into two sections; the right section in the dashedlines represents the pneumatic structure on the rock crusher section130, while the left side of FIG. 4 in the dashed line enclosurerepresents the pneumatic structure on the material feed section 110.

Referring to the left section of FIG. 4, there is shown an independentheight adjustable air supply line 402 and an independent heightadjustable air supply line quick coupler component 404. FIG. 4 shows twoindependent lines of differing length. In an alternate embodiment, oneline could be used as the connection between independent heightadjustable air supply line quick coupler component 404 andtractor-to-trailer air supply line quick connect coupler component 406.This connection would not occur at the same time as a connection betweenindependent height adjustable air supply line quick coupler component404 and inter-section independent suspension height quick connectcomponent 416. Independent height adjustable air supply line quickcoupler component 404 and tractor-to-trailer air supply line quickconnect coupler component 406 may be standard airline quick connect orproprietary quick connects, if desired.

Independent height adjustable air supply line 402 provides air to feederair supply reservoir 420, which provides air to the brake system (ifdesired) and to feeder suspension height valve 424, which adds orexhausts air to the feeder suspension air bag 428 via feeder section,independent to common suspension control valve 422. Coupler 414, andinter-section common suspension height quick connect component 440,provide air to common supply line 412, which provides air to feedersection independent to common suspension control valve 422 to shuttlefeeder section independent to common suspension control valve 422 andoverrides feeder suspension height valve 424 and provides pressure tofeeder suspension air bag 428, resulting in a common pressure in all airbags. Feeder suspension height valve 424 could be an industry standardheight control valve or any suitable substitute. Feeder sectionindependent to common suspension control valve 422 could be a pilotvalve, manual valve or any suitable substitute, which diverts or directsair pressure either from valve 424 (for independent travel) or fromcommon supply line 412. Feeder suspension height valve 424 is coupled tofeeder section independent to common suspension control valve 422 andvia feeder suspension linkage 430 and suspension arm 431.

On the right side of FIG. 4, there is shown a tractor-to-trailer airsupply line quick connect component 454 coupled to a crusher sectionmain air supply quick connect component 452 and via crusher section mainair supply line 450 to crusher section air supply reservoir 456, whichprovides air to the brake system (not shown) and to crusher sectionsuspension height valve 460, which is coupled to a suspension arm 431 bysuspension linkage 466.

Crusher section suspension height valve 460 is coupled via crushersection suspension supply line 462 to the various crusher sectionsuspension air bags 464 and also to manual shut-off 446 and viainter-section common suspension height supply line 442 to inter-sectioncommon suspension height quick connect component 440, which couples itto feeder section independent to common suspension control valve 422, asdiscussed above, to provide for common suspension height control whenmaterial feed section 110 and rock crusher section 130 are combined. Theair suspension system of the present invention can be designed so thatonly one axle is monitored for height control and the other axles areonly pressure controlled. The primary purpose would be focused on anequalized axle load, not equal height control. The actual lengths of theair bags would vary due to frame deflection, frame slope, or groundlevel.

Crusher section main air supply line 450 is coupled via crusher sectionindependent suspension height supply line 458 to inter-sectionindependent suspension height manual shut-off 444, which is coupled tointer-section independent suspension height quick connect component 416.

The material feed section 110 and rock crusher section 130 can be usedand then separated using the following process:

1. Towing tractor is attached to front of combined chassis; i.e., tofront of rock crusher section 130 and airlines are attached at crushersection main air supply quick connect component 452.

2. Air system, including both feeder air supply reservoir 420 andcrusher section air supply reservoir 456, is charged from towingtractor.

3. Disconnect rear chassis suspension air lines, both independent heightadjustable air supply line 402 and common supply line 412 and electricallines; this thereby locks the rear axle and applies the brakes.

4. Disconnect mechanical latch of some type to enable relative movementbetween the chassis.

5. Tow rock crusher section 130 chassis forward, sliding under materialfeed section 110 chassis until contact with a slide stop.

6. Start material feeder section gas-powered hydraulic pump 310 andunfold material feeder trailer jack 210 to vertical position.

7. Extend material feeder trailer jack 210 to lift material feed section110 chassis above slide stop.

8. Tow rock crusher section 130 chassis away from material feed section110 chassis.

9. Back the feeder tow tractor into position under material feed section110 chassis.

10. Use material feeder trailer jack 210 to adjust height to allowengagement with towing tractor.

11. Continue backing tractor into material feed section 110 chassisuntil king pin locks engagement.

12. Hydraulically retract and fold material feeder trailer jack 210 andturn off material feeder section gas-powered hydraulic pump 310.

13. Attach air and electric lines to towing tractor.

14. Turn manual rear axle brake valve to “off” position. (In someembodiments, this step may be omitted.)

In an alternate embodiment, to separate the feeder from the crusher,leaving the crusher in place, you could repeat steps 1 through 3, thenrelease the brakes in axle 114 while retaining pressure in the air bag428, then release the mechanical latch, thereby allowing relativemovement aided by a hydraulic or winch-type system to move chassis 110backwards to the mechanical stop.

Also, rollers could be used to further facilitate relative movement ofthe two chassis.

The terms “road building materials” are used throughout this descriptionas an example of a common use of aggregate materials. It should beunderstood that the terms “road building materials” are intended toinclude aggregate materials, irrespective of the actual use to whichsuch aggregate materials may be put. Similarly, the terms “rock crusher”are used as a common example of the use of a crusher; however, the terms“rock crusher” are intended to include any crusher, whether it is rock,concrete, or any other material that is being crushed.

It will be understood that certain features and sub-combinations are ofutility and may be employed without reference to other features andsub-combinations. This is contemplated by and is within the scope of theclaims.

Now referring to FIGS. 6 and 7, there is shown an array of product pilesand a system for processing road building materials. There is shown abifurcatable crusher 100, a surge bin material transfer apparatus 200,and scalping screen 300 and a scalping screen to secondary cone inputconveyor 302 and a secondary cone bypass conveyor 304, which deliversthe output of scalping screen 300 to the output of secondary conecrusher 400 without running the material through secondary cone crusher400.

Bifurcatable crusher 100 can be a jaw crusher, such as thosemanufactured by Cedarapids Inc., or other type which has a significantweight which would exceed a maximum weight for a trailer to travel asone complete unit.

Scalping screen 300 may have various sized screens therein, but in oneembodiment, it might have screens of the following sizes: 2.5 inches topdeck, 1.25 inches middle deck, and a 0.875 inches bottom deck, all being6′×20′. Scalping screen 300 is shown outputting two (2) stockpiles, witha total of five (5) stockpiles for the entire system, but it should beunderstood that one embodiment of the present invention is capable ofsimultaneously outputting seven stockpiles, five of which could beblended (material which is known to be separated to different sizeranges and then later combined). More details of the design andoperation of scalping screen 300 will be understood when referring toFIG. 10 below.

Secondary cone crusher 400 has one output conveyor, secondary coneoutput conveyor 470, which accepts material from three sources, theoutput of the secondary cone crusher 400, the secondary cone bypassconveyor 304 (at a common height), and the output conveyor of thetertiary cone crusher 500 (at a common height). In one embodiment,secondary cone crusher 400 could be an MVP-type cone crusher, asmanufactured by Cedarapids, Inc., with a one-inch output setting.Secondary cone output conveyor 470 feeds finish screen 600 (at a commonheight) which has four (4) output conveyors, three (3) of which delivermaterial to stockpiles and another which loops material back around viatertiary cone crusher 500 to secondary cone output conveyor 470 (at acommon height) and then back through finish screen 600.

Tertiary cone crusher 500 could also be an MVP-type cone crusher and, inone embodiment, could have a ½-inch output setting. Tertiary conecrusher 500 also has a common feed point height that is set to cooperatewith the common output conveyor height of the scalping screen 300 andfinish screen 600.

Finish screen 600 could, in one embodiment, be a triple deck screen witha 0.75-inch top deck, a 0.5-inch middle deck, and a 0.25-inch bottomdeck, all of which could, in one embodiment, be an 8′×20′ screen.

With the common output conveyor heights and the common feed pointheights of the various components to the system, it is possible tocustomize a solution for a particular specification or application. Forexample, the mini plant of FIG. 5 is enabled because of the commonoutput and feed point heights across the various components. Controltrailer 700 is the central control and power source for the variouscomponents. In one embodiment, the control trailer 700 may provide onlycontrol signals leaving the power supplying function to the generators704 and 706. In another arrangement, control trailer 700 could provideboth. In still other embodiments, control trailer 700 could providepower, as well as additional generators 704 and 706. Power supply andcontrol wires 702 would connect the control trailer 700 with the variouscomponents. Having a small footprint for the system allows for shortpower supply lines between the control trailer 700 and the various othercomponents. The shorter the power supply lines, the less resistance andthe concomitant energy loss associated therewith. With less energy loss,a smaller generator can be used, thereby conserving fuel costs. Also,with shorter power supply lines, which are typically much larger thanthe lines that merely provide control signals, you get less weight andeasier and quicker setup times. Alternatively, each component could haveits own engine/generator system and could be connected together via awired or wireless network.

It should be noted that the system of FIGS. 6 and 7 does not have anystand-alone single purpose inter-plant conveyor trailers; i.e., eachconveyor in the system of the present invention is coupled to andcombined with and transported as part of a function piece of equipment,which provides a function other than merely conveying material. Thesurge bin material transfer apparatus 200 provides the function ofbuffering irregular flows by temporarily storing material exiting thebifurcatable crusher 100 at times of high output flow. Additionally, inone embodiment, all of the inter-plant (between screen, crusher, andsurge bin) conveyors used in the entire system are not configured toprovide substantial vertical height adjustment of the discharge point.The use of such common discharge point heights from the variousinter-plant conveyors enables faster setup times while preserving theability to move the screens and crushers around to form different systemconfigurations. One of the innovative methods of the present inventionis to rearrange, add to, or omit from a first system, screens, crushersand surge bins, and thereby create a different combination withoutmaking any horizontal or vertical adjustments of the any dischargepoints of any inter-plant conveyors. The use of common discharge andcommon feed points for the various screens, crusher and surge binsallows for this to occur.

The various screens, crushers, etc. are shown with wheels and tiresthereon for providing the ability to transport them on a highway.However, it should also be understood that some embodiments of thepresent invention might include tracks instead of tires or in additionto tires. Even if the system is designed with tracks, many of thebeneficial aspects of the invention are still achieved.

Now referring to FIG. 5, there is shown an overhead perspective view ofa “mini-plant” embodiment of the present invention, which has fewermajor components and occupies a smaller footprint than the system asshown in FIGS. 6 and 7 and provides fewer stockpiling conveyors. Inparticular, there is shown a system comprising bifurcatable crusher 100,a scalping screen 300 and a secondary cone crusher 4000 and a controltrailer 700. Screen plant exiting conveyor 4300 provides material to thestockpiling conveyor 4310. Numerous other stockpiling conveyors are fedby similar exiting conveyors. The scalping screen 300 has a returningoutput conveyor 4200, which provides an output with predeterminedcharacteristics to the surge bin 4100, which feeds the cone crusher feedconveyor 4400, which delivers the material to the top opening of thecone crusher 4500, which then provides an output on conveyor 4600 to anoutput conveyor on bifurcatable crusher 100, which then delivers thematerial directly to an input onboard conveyor for the scalping screen300, where the material is screened a second time and delivered to theappropriate stockpiles. With the mini-plant, it may be necessary to giveextra care to the rate and nature of material entering the bifurcatablecrusher 100, as there is no surge capacity as is provided by the surgebin material transfer apparatus 200 of FIGS. 6 and 7. The mini plantdoes have a further advantage in that the power supply lines from thecontrol trailer 700 are shorter, thereby reducing energy loss related toelectrical resistance, which increases with length of the power supplylines. The mini plant as shown in FIG. 5 could be operated withoutadditional generators, where the only source of power is the controltrailer 700. The lack of independent conveyor trailers deployed inbetween the crushers and screens and the necessary space to maneuversuch trailers is noticeable, especially with respect to the mini plant.However, in some embodiments, it is desired to leave space between thetrailers sufficient to allow small skid steer-type loaders to gainaccess to areas where cleanup is needed. The present invention, with allconveyors being disposed onboard a trailer containing structure toperform a function additional to merely transporting the material,provides the ability for this small footprint. Additionally, in oneembodiment, all of the inter-plant (between screen, crusher, and surgebin) conveyors used in the entire system are not configured to providesubstantial vertical height adjustment of the discharge point. A surgebin material transfer apparatus 200 (FIGS. 6 and 7) is understood toprovide a buffering ability to accommodate substantial surges in outputof a crusher or diminution in acceptance by a screen. Note thatstructure at the very end of a conveyor which helps to deflect materialand provides only very minor buffering ability, such as the deflectingstructure 1907 (FIG. 19), is considered herein and in the claims not toprovide substantial buffering for surges. The multiple common feed pointheight and output conveyor heights allow for flexibility in configuringan aggregate processing system for a particular need.

Now referring to FIG. 8, there is shown an upwardly looking perspectiveview of the scalping screen 300, which displays the multiple commonconveyor output aspect of the present invention, which includes thescalping screen to secondary cone input conveyor 302 (at a first commonheight), secondary cone bypass conveyor 304 (at a second common height)and the first under conveyor tail 3002 coupled to the first underconveyor head 3012 (at a third common height). Also shown is the secondunder conveyor tail 3004, which coupled to a conveyor head 3014 (FIG.13). Also shown is the scalping screen fines collection conveyor 3008,the scalping screen blending conveyor 3010, the scalping screen secondblending conveyor 3016, and the scalping screen frame 3006.

Now referring to FIG. 9, there is shown a close-up view of the outputand blending end of the scalping screen 300, which includes: first finesblending chute 3020 which contains gate assembly 1008 and acceptsmaterial from lower blending chute to fines blending chute transferchute 3032 and scalping screen fines collection conveyor 3008 anddelivers the same to scalping screen blending conveyor 3010 and/or tofirst under conveyor tail 3002. Lower blending chute to fines blendingchute transfer chute 3032 accepts material from lower blending chute3030, which contains gate assembly 1006 and variably provides materialto lower blending chute to fines blending chute transfer chute 3032and/or lower blending chute to blending conveyor transfer chute 3034.Lower blending chute to blending conveyor transport chute 3034 providesmaterial to scalping screen second blending conveyor 3016. Upperblending chute 3040, which contains gate assembly 1004, variablyprovides material to lower blending chute 3030 and/or transverseblending chute 3050. Transverse blending chute 3050, which contains gateassembly 1010, variably provides material to scalping screen secondblending conveyor 3016 and/or second under conveyor tail 3004, viapant-leg chute 3036. Note that pant-leg chute 3036 comprises twoseparate chutes that straddle scalping screen blending conveyor 3010 andscalping screen second blending conveyor 3016.

Now referring to FIG. 10, there is shown a flow diagram of arepresentative process of the present invention. The material sizes andthroughput rates in tons/hour (t/h) are not intended to be limiting, butto provide details of one embodiment of the present invention operatedunder one representative evaluation scenario. Note the dashed linesrepresent material paths that did not carry material in the selectedevaluation scenario. The process begins with bifurcatable crusher 100crushing material to be processed, then surge bin material transferapparatus 200 transports the material to the scalping screen 3300, whereit is graphically depicted as having three (3) stacked screens, top deck3102, mid deck 3104 and lower deck 3106. Note that scalping screen 3300is similar to scalping screen 300 of FIGS. 6, 7, 8, and 9 with onesignificant difference being the number of sliding swing gate blendingassemblies, that are included in scalping screen 3300, is more than thenumber in scalping screen 300, and the number of stockpiling conveyorscould be different. It is believed that once the sliding swing gateblending assembly 1500 (FIGS. 15-18) is understood and the innovativeinstruction to substitute is made herein, then the substitution would becapable of being carried out by one having ordinary skill in the art.The overs of top deck 3102 are provided to scalping screen to secondarycone input conveyor 3302 (which is similar to conveyor 302) and then onto secondary cone crusher 400. The overs of mid deck 3104 are providedto gate assembly 1002, which could be an array of selectively pluggableholes or, like all of the other gates herein, be either a swing gate ora sliding swing gate or any suitable substitute, which can direct thematerial either to secondary cone crusher 400 or to the sliding swinggate blending assembly 1004, the output of which is directed either tosliding swing gate blending assembly 1010 or to sliding swing gateblending assembly 1006, where the overs of lower deck 3106 are alsoreceived. (Note: when the term “sliding swing gate blending assembly” isused, it is intended to include, but is not necessarily limited to, agate which is capable of infinite, but not necessarily continuousvariation in flow from 0-100%.)

The output of sliding swing gate blending assembly 1006 is directed toeither stockpile 1018 or to sliding swing gate blending assembly 1008,which can send the material to either stockpile 1014 or to sliding swinggate blending assembly 1012, which feeds either stockpile 1020 orsecondary cone bypass conveyor 3304 to conveyor 1022, which providesmaterial to finish screen 600 and tertiary cone crusher 500. Conveyor1022 of FIG. 10 represents the very same conveyor secondary cone outputconveyor 470.

One noteworthy feature of the scalping screen 3300 is that, in oneembodiment, there is a stacked series of four gravity-fed diverters forvariably directing the middle deck overs. Material which passes throughthe top deck, but not through the middle deck, encounters gate assembly1002, then sliding swing gate blending assembly 1004, then on to slidingswing gate blending assembly 1006, after which it is blended with thebottom deck throughs, then on to sliding swing gate blending assembly1008. The material then goes on with the aid of an intermediate conveyorfinally to yet another, the fifth diverter onboard scalping screen 3300,sliding swing gate blending assembly 1012.

The output of sliding swing gate blending assembly 1010 is to eitherstockpile 1016 or 1018.

The output of secondary cone crusher 400 and secondary cone bypassconveyor 3304, which is similar to secondary cone bypass conveyor 304,is combined to conveyor 1022 and then provided to finish screen 600,which is also a three-deck screen, similar in style to scalping screens3300 and 300, but with finer screens for more precise discrimination ofmaterials, and it may have different discharge chutes and conveyors. Theovers of finish screen top deck, which could be a ¾-inch screen, go totertiary cone crusher 500. The overs of the mid deck, which could be a½-inch screen, go to sliding swing gate blending assembly 1100 (whichcould be similar to gate assembly 1002), which provides material toeither sliding swing gate blending assembly 1102 (which could be similarto gate assembly 1004) or to tertiary cone crusher 500. Sliding swinggate blending assembly 1102 provides material to either sliding swinggate blending assembly 1104 (which could be similar to gate assembly1006) or sliding swing gate blending assembly 1108 (which could besimilar to gate assembly 1010). All gate assemblies herein couldvariably divert material to one location and/or another location.

The overs of the lower deck, which could be a ¼-inch screen, go tosliding swing gate blending assembly 1104, which directs such materialto either sliding swing gate blending assembly 1106 (which could besimilar to gate assembly 1008) or a stockpile.

The fines of finish screen 600 can go to sliding swing gate blendingassembly 1106, which can go to a fine stockpile or be blended with othermaterial and delivered to a stockpile. The output of tertiary conecrusher 500 is returned to finish screen 600, where it is processedagain and directed eventually to the appropriate stockpile.

The present invention provides a level of blending control, which hasbeen very difficult to achieve in a mobile aggregate crushing system.Often road builders will give a specification for base aggregate ofhaving a maximum percentage of fines less than X inches. Often operatorsof rock crushers and aggregate processing systems would attempt tominimize the fines in the delivered road blend product. Thisminimization of the fines results in a higher level of less desirablerock. With this level of control, it provides the plant operator withthe ability to include a controlled amount of fines (just under thelimit of the road blend specification) instead of building a largerstockpile of waste rock. This notion of transforming otherwise wasterock into usable material results in increased profits for the plant.

Now referring to FIGS. 11 and 12, there are shown perspective views of aportion of the scalping screen 300, which includes the top deck 3102,mid deck 3104, lower deck 3106 and the discharge lip 3108, whichcollectively are called the triple deck screen 3100.

Also shown is the scalping screen blending conveyor 3010, first underconveyor head 3012 and the secondary cone bypass conveyor 304. Alsoshown is scalping screen to secondary cone input conveyor 302.

Now referring to FIGS. 13 and 14, there are shown perspective views of aportion of scalping screen 300 removed to reveal underlying importantstructure which otherwise would be occluded from view. Shown istransverse chute assembly 3050, which contains gate assembly 1010.Material from chute assembly 3050 can variably discharge to scalpingscreen second blending conveyor 3016 and/or second under conveyor tail3004 (FIG. 8) and second under conveyor head 3014.

Some of the beneficial aspects of the present invention are provided bythe novel features of the sliding swing gate blending assembly 1500shown in FIGS. 15-18.

In general, each of the sliding swing gate blending assemblies 1500,located at various points in the scalping screen 300, have a fixedmaterial entry top chute 1502 and a fixed backward flow exit chute 1522and a fixed forward flow exit chute 1520. Disposed therebetween are themovable parts; i.e., the sliding and swinging portions of the slidingswing gate blending assembly 1500.

Referring in detail now to FIG. 15, there is shown a sliding swing gateblending assembly 1500 of the present invention, shown from a top viewwith the chute located thereabove removed to provide for easiervisualization of the sliding swing gate blending assembly 1500. Alsoremoved are covers which form in part the backward flow exit chute 1522and forward flow exit chute 1520. The top or entrance chute, whichprovides material to sliding swing gate blending assembly 1500, wouldextend upwardly; i.e., toward the viewer and perpendicular to the planeof FIG. 15. Sliding swing gate blending assembly 1500 includes a slidingfixed backflow directing plate 1506 which, if exposed or partiallyexposed to the material entering through material entry top chute 1502,will always direct material in a backward direction. Also shown issliding fixed forward flow directing plate 1510 which, if exposed orpartially exposed to the material entering through material entry topchute 1502, will always direct material in a forward direction. Disposedbetween sliding fixed forward flow directing plate 1510 and slidingfixed backflow directing plate 1506 is sliding swing gate 1512, whichcan be pivoted or swung in one direction or the other to selectivelydirect material in either the forward or backward direction. Slidingswing gate 1512 is shown in FIG. 15 pivoted in a forward direction,which mimics the positioning of sliding fixed backflow directing plate1506 and, therefore, results in material exiting through backward flowexit chute 1522.

Sliding fixed backflow directing plate 1506, sliding swing gate 1512 andsliding fixed forward flow directing plate 1510 may be coupled in alinear fashion, so that they can all be forced to slide or translateback and forth as a single unit. Sliding swing gate 1512 is alwayslocated fully within the material contacting portion sliding swing gateblending assembly 1500, and the sliding fixed backflow directing plate1506 and sliding fixed forward flow directing plate 1510 may be locatedbetween 100% to 0% within the zone under material entry top chute 1502which contacts the material.

As the sliding swing gate 1512 pivots from one position to the next, itis bounded on one side by the sliding swing gate backward side limitplate 1514 and on the opposing side by the sliding swing gate forwardside limit plate 1516. When sliding swing gate 1512 is fully deployed toone position, the top end of sliding swing gate 1512 rests upon eitherthe sliding swing gate rear rail 1530 or the opposing sliding swing gatefront rail 1532, which together also provide for structural support ingeneral of the sliding swing gate blending assembly 1500. Sliding swinggate 1512 is shown in FIG. 15 while in the process of pivoting betweenoperating positions. The translational position of sliding swing gate1512 is shown at approximately a 25 to 75 percent sharing setting. Assliding swing gate forward side limit plate 1516 moves closer, duringthe incremental adjustment process, to forward side end plate 1556, thesharing percentage between forward diversion and backward diversion willchange and become more extreme; e.g., a ten percent to ninety percentsharing setting. Then as sliding swing gate forward side limit plate1516 contacts endplate 1516, the sharing will be 0 to 100 percent.However, if the sliding swing gate 1512 were then pivoted, it wouldbecome a 50-50 sharing.

In operation, the sliding swing gate blending assembly 1500 couldfunction as follows:

Material is output from a source of material, either overs, fines or apreviously blended combination of the same. The material goes through amaterial entry top chute 1502 and drops upon the sliding swing gateblending assembly 1500. Depending upon the positioning under thematerial entry top chute 1502 of the slide assembly (which comprisessliding fixed backflow inclined directing plate 1506, sliding fixedforward flow inclined directing plate 1510 and sliding swing gate 1512),the material will flow in some set percentage to either the forward flowexit chute 1520 or the backward flow exit chute 1522. If a different mixof percentages is desired, then the slide assembly of sliding fixedbackflow directing plate 1506, sliding swing gate 1512 and sliding fixedforward flow directing plate 1510, can be slid one way or the other tomake an infinitely variable diversion of material through the slidingswing gate blending assembly 1500. While the sliding swing gate blendingassembly 1500 is capable of infinite variability, it should beunderstood that the variations are not necessarily continuous. To gofrom a mixture with 47% forward, then to 49% forward, and finally to amixture of 51% going forward, requires more than a continuation of themovement which resulted in an increase from 47% to 49%. The processwould involve both flipping the sliding swing gate 1512 and sliding thesame gate nearly completely to one side of the space under materialentry top chute 1502; i.e., either minimizing or maximizing the gapbetween sliding swing gate forward side limit plate 1516 and end plate1556.

It is believed that the combination of a sliding and swing gate providefor the ability to have a fully adjustable flow while reducing thevertical height of the apparatus to selectively divert flow. The smallvertical height of sliding swing gate blending assembly 1500 allows forthe more sliding swing gate blending assemblies 1500 to be stackedwithin the area below the output of the various screens of scalpingscreen 300. Therefore, this novel component provides for increasedcompactness of the scalping screen 300 with a high degree of blendingcontrols.

Now referring to FIGS. 19-23, there is shown a side view of a foldingconveyor 1900 of the present invention, together with a hopper/materialintake location 1902, disposed in a position to receive material fromthe folding conveyor 1900. Hopper/material intake location is simplyshown as an arrow to suggest the orientation of a side of the hopper andthe flow direction of material in the hopper, etc. It should beunderstood that much more structure would be associated with such ahopper, and the arrow is merely intended to indicate the intake locationor a side of the hopper.

Folding conveyor 1900 has a folding conveyor discharge end 1904 and afolding conveyor intake end 1906, and is divided into two sections whichare movable with respect to each other, folding conveyor dischargesection 1910 and folding conveyor intake section 1912, which are joinedby folding conveyor section hinge 1914. Folding conveyor 1900 could bemounted to a material intake of scalping screen 300, an intake of thesurge bin material transfer apparatus 200 or a stand-alone dedicatedtrailer, or it could be mounted to a trailer also carrying additional orother functional components. A folding conveyor central cam/arch 1920 ispivotally (capable of being pivoted) coupled at one point to a base,such as a trailer (not shown). Folding conveyor intake arm linkage 1922is pivotally coupled at one end to folding conveyor central cam/arch1920 and at an opposing end to folding conveyor intake end 1906. Foldingconveyor midrange arm linkage 1924 is pivotally coupled at one end tofolding conveyor central cam/arch 1920 and at an opposing end to anintermediate position of folding conveyor discharge section 1910.Folding conveyor intermediate arm linkage 1926 is pivotally coupled atone end to folding conveyor central cam/arch 1920 and at an opposing endto folding conveyor cam/drive head 1928.

Folding conveyor intermediate cam/drive head 1928 is pivotally attachedto link 1926 and also pivotally attached to head support 1930 andhydraulic cylinder to intermediate cam connecting linkage 1936. Theattachment to folding conveyor intermediate arm linkage 1926 andhydraulic cylinder to intermediate cam connecting linkage 1936 are atthe same point. Linkage arm 1932 is pivotally coupled to connectinglinkage 1936 at pin 1992. Hydraulic cylinder 1934 attaches to an ear onlinkage arm 1932.

In operation, the folding conveyor is caused to retract from thehopper/material intake location 1902, as would happen when a job isfinished and the folding conveyor 1900 is being readied for transport.The simple automated operation of the folding conveyor 1900 results in areduced overall height and length, as well as increased separation fromthe hopper/material intake location 1902. The points of attachment tothe trailer (not shown) are the free ends of hydraulic cylinder 1934,folding conveyor cam/drive head 1928, hydraulic cylinder distal end tovehicle linkage arm 1932 and folding conveyor central cam/arch 1920(adjacent to the point where hydraulic cylinder 1934 is coupled to thetrailer). It is possible that hydraulic cylinder 1934 is the onlyhydraulic cylinder, or other power assisting mechanism, used tosuccessfully simultaneously retract, lower the overall height andshorten the overall length all with one sweeping motion initiated with asingle actuation on the single control coupled to and controlling thehydraulic cylinder 1934. In one embodiment, the same linkage, etc.structure shown in FIG. 19 is disposed on the opposite side of thefolding conveyor 1900 (see FIG. 24).

The folding conveyor central cam 1920, and said folding conveyorintermediate cam 1928, are configured so that when said hydrauliccylinder 1934 is extended, the folding conveyor discharge section 1904first retracts away from, then drops below a receiving bin 1902location, while the folding conveyor intake section 1907 moves firstdownward and inward, so that an overall height characteristic is lessand an overall length characteristic is less than when said hydrauliccylinder 1934 is retracted.

In FIG. 19, the three pivot points 1990, 1992 and 1994 are in alignment,enabling a retaining pin 1996 to be inserted through a pin receivinghole 1998 (FIG. 20) to lock the folding conveyor 1900 in an operatingposition.

FIGS. 20-23 show the folding conveyor 1900 in configurations ofincreasing departure from the operating position of FIG. 19.

FIG. 24 is a perspective view of the scalping screen 300 shown with thevarious conveyors stowed.

FIG. 25 shows the material feeder section input hopper 112 with thematerial feeder section folding wings 118, where, for illustrativepurposes, one material feeder section folding wing is folded down fortransport, while the other is deployed in an operating position.

More specifically, there is shown a hydraulic cylinder 2500, whichpushes link 2502 beyond a toggle point, which is defined when all threepivot pins 2506, 2508, and 2510 are in alignment, which locks thematerial feeder section folding wings 118 in place by pushing against anadjustable stop 2512 mounted on the material feeder section input hopper112 body. When hydraulic cylinder 2500 pushes the links 2502 and 2504beyond the toggle point, then the weight of the material feeder sectionfolding wings 118 and any load thereon causes the link to move closer tothe adjustable stop 2512 without further application of force by thehydraulic cylinder 2500. This results in longer life of the seal in thehydraulic cylinder 2500 and allows for the hydraulic cylinder 2500 to beremoved, repaired or replaced while the material feeder section foldingwings 118 are deployed in an operating position. To stow the materialfeeder section folding wings 118, the hydraulic cylinder 2500 pulls thelink 2502, which then causes the link 2504 to also move away from theadjustable stop and to a stowed position for transport.

Now referring to FIG. 26, there is shown a perspective view of aconfiguration of a finishing screen 600 of the present invention withfour conveyors, which is similar to the scalping screen 300. Wherenumerals are used which are common with the scalping screen 300, thedifferences between the finishing and scalping screens are believed tobe minor.

Now referring to FIG. 27, there is shown a finishing screen 600 of FIG.26, which shows various flows of overs materials from the various decks.Top deck 3102 is shown with an output of top deck over material, whichclearly directs such material to the scalping screen to secondary coneinput conveyor 302. Overs from mid deck 3104 are directed through firstfines blending chute 3020. The sliding swing gate blending assembly 1100can take the form of four pluggable holes in a floor portion of thedischarge lip or other gates of the present invention.

Now referring to FIG. 28, there is shown a perspective view of aconfiguration of a scalping screen 300 of the present invention with acone bypass conveyor.

The function of the present invention could be better understood by nowreferring to FIG. 29. There is shown a scalping screen 300 of FIG. 28,which shows various flows of overs materials from the various decks. Theflows from the various decks are shown directed through the gates and onto the scalping screen to secondary cone input conveyor 302 and thesecondary cone bypass conveyor 304. Sliding swing gate blending assembly1002 can take the form of four pluggable holes or other variations ofthe gates of the present invention.

Since many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative and not in a limiting sense.

We claim:
 1. A mobile screen comprising: a plurality of decks forseparating aggregate material having differing dimensionalcharacteristics; aggregate material diverter wherein flow of materialtherethrough is substantially aided by gravity; wherein said aggregatematerial diverter is an infinitely adjustable material diverter, capableof dividing input flows therein to a plurality of output flows; saidinfinitely adjustable material diverter comprises: a gate which isconfigured to move, in a first manner, to block, at least portions of afirst passage, while permitting aggregate material to flow through asecond passage; and said gate further configured to move, in a secondmanner, across an area below a material flow so that movement of saidgate, in said second manner, results in an infinitely adjustablepercentage of permissible flow through said first passage and saidsecond passage; and a vehicular structure supporting said plurality ofdecks and said aggregate material diverter.
 2. The mobile screen ofclaim 1 wherein said plurality of decks are a plurality of stackeddecks.
 3. The mobile screen of claim 1 wherein said first manner is oneof a pivoting motion and a translating motion.
 4. The mobile screen ofclaim 3 wherein said second manner is another one of said pivotingmotion and said translating motion.
 5. The mobile screen of claim 4wherein said first manner is said pivoting motion and said second manneris said translating motion.
 6. The mobile screen of claim 1 wherein saidgate is a pivotable gate which is configured to block a first passagewhile permitting aggregate material to flow through a second passage;and said pivotable gate is further configured to move, in a non-pivotingmanner, in an area below a material flow so that a movement of saidpivotable gate, in said non-pivoting manner, results in an infinitelyadjustable percentage of permissible flow through said first passage andsaid second passage.
 7. The mobile screen of claim 6 where said movementof said pivotable gate in said non-pivoting manner is a translatingmovement.
 8. A mobile screen comprising: a stacked series of decks forseparating aggregate material having differing dimensionalcharacteristics; a series of aggregate material diverters wherein flowof material therebetween is substantially aided by gravity; wherein oneof said series of aggregate material diverters is an infinitelyadjustable material diverter, capable of dividing input therein toalternate output flows in any increment from all input to none of theinput; and a vehicular structure supporting said stacked series of decksand said series of aggregate material diverters, where said vehicularstructure is configured with all appendages thereto to be transported ona public highway.
 9. A mobile screen comprising: a stacked series ofdecks for separating aggregate material having differing dimensionalcharacteristics; a series of aggregate material diverters wherein flowof material therebetween is substantially aided by gravity; wherein oneof said series of aggregate material diverters is an infinitelyadjustable material diverter, capable of dividing input therein to aplurality of output flows in any increment from all input to none of theinput; and a vehicular structure supporting said stacked series of decksand said series of aggregate material diverters, where said vehicularstructure is configured to be transported on a public highway.
 10. Themobile screen of claim 9 wherein said infinitely adjustable materialdiverter comprise a gate, movable in a first movement manner and asecond movement manner, wherein said first movement manner is inrelation to a first reference line and said second movement manner is inrelation to a second reference line.
 11. The mobile screen of claim 10where said first reference line has a constant angular relationship withsaid second reference line.